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- IN3PV
- Installation, Operating And Service Instructions
U.S. Boiler Company IN3PV Installation, Operating And Service Instructions
103560-03 - 10/12
Price - $5.00
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For service or repairs to boiler, call hour heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
IN_PVSNI_
Boiler Serial Number
Installation Date
Heating Contractor
Phone Number
Address
9700609
Summary of IN3PV
Page 1
103560-03 - 10/12 price - $5.00 d n a g n i t a r e p o , n o i t a l l a t s n i r o f s n o i t c u r t s n i e c i v r e s e c n e d n e p e d n i ® v p r e l i o b d e r i f - s a g for service or repairs to boiler, call hour heating contractor. When seeking information on boiler, provide boiler...
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2 figure 2: tapping locations table 2: purpose of tappings table 1: dimensions and clearances the following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. The new york city department of...
Page 3
3 figure 1: elevation views warning this boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and und...
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4 i. Pre-installation f. Provide combustion and ventilation air in accordance with applicable provisions of local building codes, or national fuel gas code, nfpa 54/ansi z223.1, air for combustion and ventilation. The following guideline is based on the national fuel gas code, nfpa 54/ansi z223.1. 1...
Page 5
5 rating of 1 perm or less with openings gasketed and sealed, and; b. Weather-stripping has been added on openable windows and doors, and; c. Caulking or sealants applied in joints around window and door frames, between sole plates andfloors,betweenwall-ceilingjoints,between wall panels, at plumbing...
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6 iii. Steam piping and trim a. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiringadditionofmakeupwater,fittings,and oxygen permeable materials in distribution system. Eliminate oxygen contamination sou...
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7 figure 4: steam piping, in3pv figure 3: trim installation iii. Steam piping and trim (continued).
Page 8
8 iv. Gas piping a. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for addit...
Page 9
9 table 4: maximum capacity of schedule 40 pipe in cfh of natural gas for gas pressures of 0.5 psig or less table 5: fitting equivalent lengths figure 6: recommended gas piping table 6: specific gravity correction factors for natural gas 2. Use thread (joint) compounds (pipe dope) resistant toaction...
Page 10
10 notice the gasketed vent system components pictured below in figure a are being phased in and each vent component is interchangeable with the previously supplied gasket-less venting components. The newer vent components are generally quicker and easier to join, as they do not require the sealant ...
Page 11
11 table 8: vent system components c. Install vent connector. 1. Remove vent connector from vent accessory carton. 2. Removegaskets,orificeplateandhardwarefrom bloweroutletflange. 3. Assembleorificeplategaskets,orificeplate,and vent connector. See figure 7. 4. Secure vent connector with washers and ...
Page 12
12 a. Clean the male end of each joint using an alcohol pad to remove any dirt and grease. B. Apply a continuous ¼ inch bead of sealant around male end of joint no more than 1/8 inch from end. C. Align weld seams in pipes and use a slight twisting motion to fully insert male end into female end of j...
Page 13
13 figure 8c: u.S. Boiler company gasket-less female and gasketed male vent joint detail 2. Procedure for joining the female end of u.S. Boiler company gasket-less vent with the male end of u.S. Boiler company gasketed vent. See figure 8c. A.Cleanjointsofpipeorfittingsusinganalcohol pad to remove an...
Page 14
14 figure 11: vertical vent installation figure 10: horizontal vent terminal v. Venting (continued) h. Vertical (through roof) vent installation 1. Install vertical vent drain tee. See figures 11 and 12. Attach tee directly to elbow or horizontal pipe from elbow. 2. Slope horizontal runs minimum ¼ i...
Page 15
15 figure 13: attic offset figure 12: vertical vent tee installation figure 14: vertical vent termination table 9: minimum vent height above roof roof pitch minimum height [h] flat to 6/12 1 ft. Over 6/12 to 7/12 1 ft. 3 in. Over 7/12 to 8/12 1 ft. 6 in. Over 8/12 to 9/12 2 in. Over 9/12 to 10/12 2 ...
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16 figure 15: wiring diagram vi. Electrical a. General install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the national electrical code, ansi/nfpa 70. B. Install thermostat. Locate on inside wall approximately4feetabov...
Page 17
17 vii. System start-up a. Safe operation and other performance criteria were met with gas manifold and control assembly provided onboilerwhenboilerunderwenttestsspecifiedin american national standard for gas-fired low- pressure steam and hot water boilers, ansi z21.13. Figure 16: sequence of operat...
Page 18
18 table 11: green led status codes ignition module terminal designation wiring ladder diagram terminal number mv 1 mv/pv 2 pv 3 gnd 4 24v (gnd) 5 24v 6 spark 9 table 10: ignition module terminal cross-reference green led flash code a indicates next system action recommended service action off no “c...
Page 19
19 a. Pilotflamecurrentinmicroampscanbe measured using any standard micro-ammeter by inserting the meter probes into the module holes labeled flame current as shown in figure 17b. B. Flame current must be measured with pilot valve open/pilot lit but the main valve closed. C. Disconnect mv lead wire ...
Page 20
20 honeywell electronic ignition troubleshooting guide figure 18: troubleshooting guide "call for heat." power to module? (24 v nominal) no yes 30 second prepurge delay?(s8670 only) yes spark across ignitor/ sensor gap? Yes no check line voltage power, low voltage transformer, limit controller, ther...
Page 21
21 f. Check pilot burner flame. See figure 19. Flame should be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe. Figure 19: pilot burner flame g. Check main burner flame. See figure 20. Flame shouldhaveclearlydefinedinnerconewithnoyellow tipping. Orange-yellow streaks should not be...
Page 22
22 figure 21: operating instructions i. Remove main burners per procedure in section viii: service. Ii. Removegasorifices.Drillone(1)drillsize larger(drillsizeisstampedonorifice,orsee key no. 4d). Iii. Reinstallgasorificesandmainburners. Measure input rate. 6. Recheck main burner flame. 7. Returnoth...
Page 23
23 1. Fill boiler to normal waterline. 2. Follow operating instructions to place boiler in operation. See figure 21. 3. Operate boiler with steam in entire system for several days to bring system oil and dirt back to boiler. 4. Drain condensate from drain valve in wet return. Operate boiler until co...
Page 24
24 15. Fill boiler to normal water line. Follow operating instructions to place boiler in operation. See figure 21. 16. Operate boiler for at least 30 minutes after condensate begins to run hot. Follow instructions to turn off gas to appliance. See figure 21. 17. Close all radiator valves. Remove al...
Page 25
25 viii. Service instructions a. General inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions to turn off gas to appliance. See figure 21. Caution label all wires prior to disconnection when servici...
Page 26
26 figure 22: cleaning boiler flue passages 9. Inspectfluepassages.Cleanwithfluebrush.See figure 22. 10. Inspect heating surface in combustion chamber. Clean with straight handle wire brush. 12. Installfluegasbaffles. 13. Install new gasket (key no. 2e). Do not reuse existing material. 14. Install c...
Page 27
27 table 15: minimum vacuum figure 24: inlet fan vacuum measurement figure 25: l404f pressuretrol boiler model minimum vacuum in3pv -0.40 inches w.C. In4pv -0.40 inches w.C. In5pv -0.70 inches w.C. In6pv -0.70 inches w.C. Viii. Service instructions (continued) 4. Stop boiler, remove manometer and re...
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28 important product safety information refractory ceramic fiber product warning: the repair parts list designates parts that contain refractory ceramic fibers (rcf). Rcf has been classified as a possible human carcinogen. When exposed to temperatures about 1805°f, such as during direct flame contac...
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29 service record date service performed.
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30 no no no hose securely connected to canopy? Yes yes vent system free of obstructions? Yes replace blower clear obstructions no replace hose connect hose to canopy no hose free of cracks or holes? Connect manometer to suction pressure switch (see figure 24). Is suction pressure greater than: -0.50...
Page 31
31 troubleshooting tree for section vii, step e waterline above lowest permissible level? Yes replace blower after checking for broken wires and loose connections. Check dpst relay: 24 volts at coil? 120 volts at terminals '1' and '3'? 24 volts at suction pressure switch terminal 'c'? Replace relay ...
Page 32
32 ix. Repair parts key no. Description [quantity] part number in3pv in4pv in5pv in6pv 1. Section assembly 61710033 61710043 61710053 61710063 2. Canopy/blower assembly 2a canopy [1] 611100301 [1] 611100401 [1] 611100501 [1] 611100601 2b carriage bolt, 1/4 -20 x 1" [4] 80860115 2c washer, 1/4, uss, ...
Page 33
33 key no. Description [quantity] part number in3pv in4pv in5pv in6pv 3. Base assembly group 3a base tray [1] 71860391 [1] 71860491 [1] 71860591 [1] 71860691 3b base wrapper [1] 718600311 [1] 718600411 [1] 718600511 [1] 718600611 3b1 base end insulation [2] 720601 3b2 base rear insulation [1] 720600...
Page 34
34 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 4. Manifold and main burners 4a main burner [2] 8236099 [4] 8236099 [6] 8236099 [8] 8236099 4b main burner with 60° pilot bracket [1] 8236098 4c manifold [1] 82260033 [1] 82260043 [1] 82260053 [1] 82260063 4d main burner orifice, ...
Page 35
35 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 5. Gas train group 5a pilot assembly, natural gas, honeywell q3481b1206 [1] 103704-01 5b pilot orifice, natural gas honeywell 388146ne included with key no. 5a 5c compression nut/fitting, 1/8" od x 1/4 npt included with key no. 5a...
Page 36
36 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 6. Jacket 6a left side panel [1] 60410023 6b right side panel [1] 60410022 6c front removable door [1] 604100330 [1] 604100430 [1] 604100530 [1] 604100630 6d vestibule panel [1] 604100340 [1] 604100440 [1] 604100540 [1] 604100640 ...
Page 37
37 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 7a mcdonnell & miller ps-802 [1] 80160720 hydrolevel cg400-2090 [1] 80160725 7b probe, [included with 7a] ---- 8 safety valve, 3/4, 15 psi, conbraco 13-511-08 [1] 81660530 9a steam gauge, 0-30 psi, 2-1/2" dia. [1] 100325-01 9b dra...
Page 38
38 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 10. Controls 10a ignition module with prepurge, honeywell s8670e3003 [1] 100959-01 10b ignition module support bracket [1] 7016001 10c flame roll-out switch [1] 80160044 10c1 screw, sheet metal, #8 x 3/4" [1] 80860030 10d flame ro...
Page 39
39 key no. Description (quantity) part number in3pv in4pv in5pv in6pv 11. Gasketed vent accessory carton (includes 11a & 11b) 61110128 61110129 11a vent connector [1] 8116306 [1] 8116307 11b vent terminal [1] 8116310 ix. Repair parts (continued).
Page 40
40 appendix a - figures figure number page number description figure 1 3 elevation views figure 2 2 tapping locations section iii - steam piping and trim figure 3 7 trim installation figure 4 7 steam piping, in3pv figure 5 8 steam piping, in4pv, in5pv and in6pv section iv - gas piping figure 6 9 rec...
Page 41
41 appendix b - tables table number page number description table 1 2 dimensions and clearances table 2 2 purpose of tappings section iii - steam piping and trim table 3 8 rated input table 4 9 maximum capacity of schedule 40 pipe in cfh of natural gas for gas pressures of 0.5 psig or less table 5 9...
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42 service record date service performed.
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43 service record date service performed.
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44 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.